High-strength and tear-resistant leather materials and methods of manufacture

ABSTRACT

A leather substrate formed from waste leather and its method of production, particularly a leather substrate made up substantially of a collagen fibril matrix.

RELATED APPLICATIONS

This application claims the benefit of the following US patent applications: U.S. Provisional Patent Application No. 62/717,953 for “High Strength and Tear Resistant Leather Material and Method of Manufacture” filed Aug. 13, 2018; U.S. patent application Ser. No. 15/400,906 for “High Strength Leather Material” filed Jan. 6, 2017 now U.S. Pat. No. 10,131,096; U.S. patent application Ser. No. 15/400,913 for “Dispersion Processing Aids for the Formation of a Leather Material” filed Jan. 6, 2017 now U.S. Pat. No. 10,138,595; and U.S. patent application Ser. No. 15/400,923 for “High Strength Leather Material” filed Jan. 6, 2017 now U.S. Pat. No. 10,124,543, which priority applications are incorporated by reference as if fully set forth herein.

FIELD OF THE DISCLOSURE

This disclosure relates to formed leather products and their method of manufacture. Particularly, the disclosure relates to a leather substrate material formed from waste leather having improved strength and tear-resistance characteristics. De-wetting and dispersion aids that assist in de-wetting steps to remove desired amounts of moisture from interim wet lap products are described. The interim wet lap products realize improved fiber and fibril dispersion which results in improved formation and resultant physical properties in formed leather substrates.

The disclosure further relates to the formation of a composite leather substrate formed from multiple leather substrates having different compositions. Creation of a composite leather substrate from two or more component sheets of leather material allows for the use of source scrap leather that would otherwise be undesirable in a finished leather product.

BACKGROUND OF THE DISCLOSURE

Conventional leather is formed by tanning animal hides. The tanning process treats an animal hide with a variety of substances to improve and maintain leather's desirable physical characteristics for use in clothing, upholstery, luggage and like applications. The most desirable physical characteristics of tanned leather include appearance, feel, resilience to stretching, longevity, treatability with a variety of surface conditioning finishes and natural drape.

Leather's desirable characteristics are attributed in part to it being a fibrous, semi-porous material made up of an entangled, open matrix of resistant collagen fibers. Collagen fibers make up the majority of leather's composition. Collagen fibers are made up of constituent collagen fibril bundles made up in turn by smaller elongated strands of collagen protein known as collagen fibrils.

Generally, the tanning process is directed toward collagen fibers to fix chemically reactive sites on collagen fibers and to increase intramolecular salt links between adjacent collagen molecules. This links the matrix of resistant collagen fiber bundles, leaving tanned leather pliable, and occupies reactive sites that otherwise would allow leather to degrade and rot. The tanning process likewise removes other compounds from the hide that may be susceptible to degradation and/or perform other functions in the hide. Such compounds may be replaced with other materials.

Obtaining natural leather is problematic due to supply hide having varying qualities, tanning process costs, varying hide costs over time and other challenges.

The leather harvesting, tanning and preparation process produces waste leather byproducts in leather scraps and shavings. If not otherwise used, the waste leather is disposed of by landfill or incineration, creating a negative environmental impact.

Artificial leather products containing waste leather, such as bonded leather, attempt to emulate natural leather. Bonded leather is synthetic leather formed by embedding shredded leather particles into various binding materials. The shredded leather and binding material substance may be applied onto a fabric backing carrier.

Bonded leather type synthetic leathers lack the above-noted desirable characteristics of natural leather. This is due to synthetic leathers lacking the continuous matrix of resistant collagen fiber bundles found in natural leather.

The failure of known artificial and synthetic leathers that contain shredded leather particles is that the individual particles do not physically interact to reproduce or emulate the characteristics of a continuous piece of natural leather having an entangled matrix of resistant collagen fibers. Most notably, artificial and synthetic leathers suffer as lacking desirable tear resistance, drape, flexibility and other esthetic attributes.

In tests applied by a conventional tensometer, artificial and synthetic leather samples of 0.010 to 0.080 inch thickness were subjected to pulling stresses under tension to failure. Measurement of maximum applied force before failure was recorded and calculated as maximum tensile strength PSI measurements ranging generally from about 790 PSI to about 1750 PSI.

Likewise, given the inherently variable makeup of organic animal hides and tanning treatments, the tensile strength qualities of tanned natural leather can vary widely. The tensile strength of representative natural tanned leathers have been found to vary from about 2000 to 3200 PSI depending on leather quality, mechanical treatments and coatings applied to the leather.

Processes for forming other types of formed leather substrates containing shredded and fibrillated collagen leather fibers derived from waste derived leather are known. A challenge with these processes is the inability to achieve acceptable levels of fibril dispersion so that subsequently formed leather substrates have the potential for fibril-to-fibril entanglement.

Another challenge is that wet lap products that are formed mid-process are difficult to dewater and represent a limit to the degree of fibril dispersion which can be achieved in a final leather substrate product. Wet lap may refer to a sheet containing the dispersed fibrils, where particles or fibers are suspended in a fluid (such as a slurry), and the wet lap may be pressed or otherwise manipulated to eliminate or remove at least a portion of that fluid.

The interim wet lap products of these processes also tend to have low wet lap strengths. This presents processing challenges with manipulating interim wet lap products in large-scale production processes using known paper-type processing machines. During transition of the interim wet lap from wire mesh sections of paper-type processing machines, the wet lap tends to break reducing process efficiency and making it very difficult or impossible to produce the end product on a large scale.

Another challenge with prior art processes for forming leather substrates is that required leather particles must be shredded or ground to small sizes and passed through screens having likewise small apertures of approximately 3/32 (0.09375) of an inch in diameter in order to attain desired fibril dispersion and interaction between leather particles. These small grind sizes can slow processing times which reduce process productivity and also limits the ability to achieve some desired physical properties.

Yet another challenge with known processes for forming leather substrates derived from waste leather is the inability to obtain an end product having desired qualities in the outer, presentation surface of an end leather product.

Waste leather that is used in methods of producing a leather substrate may be obtained from different sources including strip waste, cuttings and scraps from the processing of source leather of various grades. Source waste leather may be higher quality full grain or top grain leather obtained from surface or top cuts of animal hide. Alternatively, source waste leather may be lower quality split grain or genuine leather obtained from inner split or bottom cuts of animal hide.

Generally, source waste leather obtained from the surface of animal hide contains leather fibers which provide higher strength and tear-resistance qualities over source leather obtained from the inner portions of animal hide. However, source waste leather derived from full grain or top grain leather often contains the residue of protective coatings and other processing agents which can interfere with the steps of properly processing leather particles, resulting in lumps or non-uniform formation of interim wet lap products as well as lumps on the surface of formed leather substrates. These imperfections can limit the use of source waste leather derived from full grain or top grain leather for the disclosed method.

Thus, there is a need for an improved formed leather product that is created from available waste leather byproducts that reproduces desirable physical characteristics of natural leather. The improved leather product should emulate the collagen fiber matrix that is found in natural leather, have predictable physical characteristics including high tear resistance, desired elastic properties for a range of end applications, and treatability by conventional leather conditioning substances. The process of creating the improved leather product should allow improved de-watering of interim wet lap products and have good wet lap strength to facilitate physically manipulating interim wet lap products. The improved leather product should also have desired qualities in its outer, presentation surface.

SUMMARY OF THE DISCLOSURE

Disclosed is a formed leather material created from commonly available waste leather byproducts and its method of manufacture. The formed leather material reliably reproduces desirable physical characteristics of natural leather, including high tear resistance, high tensile strength, desired elastic properties for end applications and treatability by conventional leather conditioning substances.

The improved leather material includes a formed leather substrate containing a matrix formed by collagen fibrils. The collagen fibril matrix is formed from entangled collagen fibrils derived from collagen fibril bundles and collagen fibers found in naturally occurring leather.

The formed leather substrate is formed by obtaining leather waste and physically processing the waste by shredding or grinding to create leather particles of desired size. The leather particles are combined with water to form a particle/water mixture. The mixture is processed to allow collagen fibril bundles within the particles to absorb a quantity of water. The water absorption swells and partially distresses the collagen fibril bundles. The partially distressed bundles are particularly susceptible to mechanical dispersion. Mechanical dispersion of the swollen, partially distressed fibril bundles extracts a high yield of constituent collagen fibrils from the bundles to the particle/water mixture. Water is then removed from the mixture through a series of de-watering steps to form a leather substrate product containing a matrix of collagen fibrils, bundles and fibers.

In disclosed process steps, the particle/water mixture is treated with various materials to facilitate manufacturing steps and the formation of a leather substrate having a desired collagen fibril matrix.

In particular, disclosed are process steps including the use of specific de-wetting and dispersion aids. These aids assist in the formation of interim wet lap products having improved qualities and improved moisture drainage rates. Improved moisture drainage rates allow for the formation of thicker interim wet lap products during process steps. This allows for formation of a thicker and more resilient leather substrate. The improved moisture drainage rates also allow for use of higher wet pressing pressures through process steps, which allow for improved fibril-to-fibril interactions to form an improved collagen fibril matrix. The improved fiber and fibril dispersion significantly contribute to the necessary fiber-to-fiber and fibril interactions to achieve improved physical properties in formed leather substrates.

The disclosed de-wetting and dispersion aids also allow the use of larger leather particles over old art methods. In disclosed process steps, source leather material may be shredded/ground and screened through apertures of up to 0.75 inches in diameter. These larger grind sizes allow accelerated processing times as well as preserve naturally occurring fiber-to-fiber interactions within leather material, allowing for formation of leather substrates having better tear resistance.

Leather products containing the collagen fibril matrix substrate have improved tensile strength qualities over known artificial and synthetic leathers. In tests by conventional tensometer, samples of leather substrate products are subjected to pulling stresses under tension to failure to determine maximum applied force measurements before failure. Measurements recorded and calculated as maximum tensile strength PSI ranged up to and over 6632 PSI, well above known artificial and synthetic leathers and many natural tanned leather samples.

Leather products containing the collagen fibril matrix substrate share the desirable physical characteristics of conventional leather and may be treated by mechanical enhancement techniques such as embossing, calendaring, staking, tumbling and so forth.

The disclosed processes allow for the formation of improved leather substrates having improved physical properties, including improved strength and tear resistance characteristics over prior-art leather substrates. In particular, a leather substrate formed according to the method disclosed herein may exhibit a tear resistance of greater than about 40 Newtons when tested in accordance with ASTM D 4704.

The disclosed processes also allow for improved processing of interim products mid-process over prior-art processes.

The disclosure also relates to the formation of a composite leather substrate that is formed from multiple leather substrates having different compositions. Creation of a composite leather substrate from two or more component sheets of leather material allows the use of source scrap leather that would otherwise be undesirable in a finished leather product. The composite leather substrate includes an outer, presentation surface having desired elastic properties for end applications including treatability with surface conditioning finishes and a high degree of smoothness.

The present disclosure further relates to the formation of a high-strength, tear-resistant multilayer composite leather substrate formed from multiple leather substrates.

The multilayer composite leather substrate incorporates leather substrate layers that do not contain process-interfering protective coating or agent residues in outer, presentation surfaces. Leather substrate layers formed from waste leather containing interfering residues are positioned as internal middle layers of the composite leather substrate.

Other features of the leather substrate will become apparent as the description proceeds, especially when taken in conjunction with the accompanying drawing sheets illustrating embodiments of the leather substrate and related method of manufacture.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of prior-art conventional tanned leather;

FIG. 2 is a cross-sectional view of a segment of a single collagen fiber bundle;

FIG. 3 is a view of a collection of fiber bundle segments found within a leather particle;

FIG. 4 illustrates a fiber bundle segment;

FIG. 5 illustrates a swollen fiber bundle segment;

FIG. 6 illustrates a formed collagen fibril matrix;

FIG. 7 is a flow chart illustrating steps in a method of forming a leather substrate;

FIG. 8 illustrates an example apparatus for producing a leather substrate material;

FIG. 9 is a cross-sectional view of a composite leather substrate; and,

FIG. 10 is a cross-sectional view of an alternate embodiment composite leather substrate.

DETAILED DESCRIPTION

FIG. 1 is a magnified cross-sectional view of conventional tanned leather 10. Leather 10 is made up by numerous elongate, entangled collagen fibers 12 that cooperate to form an open tanned leather matrix 14.

FIG. 2 is a cross-sectional representational view of a single collagen fibril bundle 16 segment made up of constituent elongated bundles of collagen fibrils 18. It is understood that FIG. 2 is a representational view and that in naturally occurring collagen fibril bundles, the constituent elongated bundles of collagen fibrils would not be aligned in uniform, parallel formation.

The disclosed leather substrate is formed from processing collected leather source material. Source material may be leather, leather scrap, leather byproducts or other forms of leather waste derived from conventional leather processing steps.

Collected leather source material is cut, ground or shredded into particles 20 of desired size containing leather material including fibril bundles 16.

In embodiments, source material leather or leather waste is cut or ground in machinery and screened through apertures varying in size from approximately 0.0625 inches to 0.75 inches in diameter to provide generally uniform leather particle pieces. Specific leather particles derived from source material may not necessarily be the same size or same size and shape.

In particular, the shredding or grinding may be accomplished through use of cutting machinery capable of cutting fibrous materials into finely controlled particle sizes. Potential cutters may be screen classifying cutters having multiple, staggered cutter blades that allow continuous, thorough shearing of leather waste. Cut particles are passed through a screen having screen apertures. These screen apertures vary in size from approximately 0.0625 inches to 0.75 inches in diameter to assure that collected particles are acceptable and likewise have specific and generally uniform size of about 0.0625 inches to 0.75 inches in diameter.

Potential cutting machinery may be a Munson brand “SCC” Screen Classifying Cutter Model No. SCC-15-SS, or like cutter.

Potential methods may include use of a Munson screen classifying cutter or like screen classifying cutter machinery that has a number of rotating cutting blades and stationary bed knives, wherein the distance between the rotating cutting blades and stationary bed knives can be adjusted. In such methods, in addition to use of a screen having screen apertures of about 0.0625 inches to 0.75 inches in diameter, the distance between the rotating cutting blades and stationary bed knives should be set to about 0.02 to 0.1 inches.

Potential cutting machinery may also be a rotary-knife mill capable of shredding source material leather or leather waste until the particles are small enough to drop through a screen having screen apertures of about 0.0625 inches to 0.75 inches in diameter.

Use of such a screen classifying cutter provides reliable formation of leather particles as a raw material for forming a leather substrate by the processes described generally in the present disclosure.

Formed waste leather particles may not necessarily all be of the same size. In particular, a percentage of particles may be generally spherical, having a diameter of anywhere between about 0.0625 inches to 0.75 inches in diameter. A percentage of particles may be less in size. Particles may also be elongate, having a cylindrical strand or thread-like structure with a major axis extending at lengths greater than 0.75 of an inch and with a cross sectional diameter of approximately 0.0625 inches to 0.75 inches in diameter.

Generated leather particles 20 of desired size, containing fibril bundles 16, are combined with a fluid, such as water, to form a particle/water mixture, also referred to as a leather/water particle mixture. Exposure to a fluid subjects fibril bundles 16 to fluid absorption, which distresses the bundles through swelling steps described below to form swollen fibril bundles 22. Swollen fibril bundles 22 contain quantities of absorbed fluid or water 23 that partially fibrillate the bonds between adjacent collagen fibrils 18. Distressed swollen fiber bundle segments 22 contain fibrillated constituent collagen fibrils 18′ as shown in FIG. 5.

Fluid or water absorption likewise distresses and partially fibrillates the bonds between adjacent collagen fibers 12 in a particle 20.

Swollen fiber bundle segments 22 are subjected to physical mixing or agitation by mechanical dispersion devices. Potential dispersion devices may be refiners such as double disk refiners or conical refiners, as known in the paper manufacturing processes. Other potential dispersion devices may be beaters, as conventionally known in paper processing machinery, such as Hollander-type beaters. The physical mixing or agitation of the fiber bundle segments 22 extracts elongate constituent collagen fibrils 18. The collagen fibrils 18 are collected and processed to form collagen fibril matrix 24 as detailed below.

In disclosed process steps, the dispersion of individual collagen fibrils 18 from collagen fibril bundles 12 may be total or partial.

Total bundle dispersion results in the complete breakdown of bundles 12 into many constituent fibrils 18.

The use of the dewetting/dispersion aids as disclosed herein facilitates the creation of partially-dispersed collagen fibril bundles 12. These partially-dispersed collagen fibril bundles 12 may have selected fibrils dislodged from an intact bundle so that individual fibrils extend away from the intact bundle. These partially-dispersed fiber bundles have individual fibrils extending therefrom that may interact with individual fibrils extending from other fiber bundles to form a collagen fiber matrix 24 in process steps as detailed below.

A collagen fiber matrix 24 formed from such partially-dispersed fiber bundles may enjoy improved physical qualities over matrices formed entirely from totally-dispersed fiber bundles as the intact larger bundles confer a degree of natural leather's drape, tear resistance and other positive qualities to produced leather substrates. The collagen fibril matrix 24 is made up of a number of individual collagen fibrils 18 derived from collagen fiber bundles 12. Each collagen fibril 18 has an elongate body having a cross-sectional diameter generally less than 10 micrometers, and a length generally many times its diameter, each collagen fibril physically engaged and entangled with adjacent collagen fibrils to form collagen fibril matrix 24. Collagen fibril matrix 24 contains a plurality of fine gaps 26 between adjacent collagen fibrils 18 to form an overall open and porous matrix structure.

Methods of forming leather substrates containing collagen fibril matrix 24 are described below.

The flowchart of FIG. 7 discloses a method 28 of producing a leather substrate containing the collagen fibril matrix from leather source material or like leather byproducts.

Starting at step 30, leather source material and/or byproduct waste is collected. Potential leather source material could be scrap leather waste byproducts produced in tanning processing steps or leather waste from articles manufacture from tanned leather.

At step 32, byproduct leather source material is shredded or ground and screened to form de-agglomerated byproduct particles 18 of a desired size. Particles are passed through a screen having screen apertures of a selected size to assure collected particles 18 are of a like selected size.

At step 34, collected particles 18 are mixed with a quantity of fluid or water to form a mixture. Typically, the particle/water mixture contains about 2% to 8% of leather particles 18 by weight.

Particles 20 become swelled with fluid or water from the particle/water mixture. While this mixture is referred to as a particle/water mixture herein, it is understood that fluid liquids other than water may be used.

Mixing at step 34 may be accomplished through use of known mechanical mixing equipment including pulpers, beaters, refiners, de-flakers or blenders.

The particle/water mixture formed at step 36 may also contain certain processing aids. These aids may be ionic salts, divalent cationic salts or combinations thereof, other processing or property modifiers, such as viscosity modifiers, alkali or acid materials to adjust pH or dyes, and pigments or bleaches to effect end-product color. Potential viscosity modifiers may include modified celluloses such as carboxy methyl cellulose and the like, polysaccharides such as pectin and various sugars, polyvinyl alcohol and polyacrylates.

In embodiments, the processing may be a polymer latex additive. In some examples, the ionic salts, divalent cationic salts or combinations thereof may be added to the water/leather particle mixture either before or after the addition of the polymer latex. Exemplary polymer latex additives may include an acrylic latex polymer such as acrylonitrile latex polymer. Suitable polymer latex additives may further include, but are not limited to, acrylonitrile-butadiene styrene (ABS), styrene-butadiene styrene, acrylonitrile-ethylene-butadiene-styrene, methyl methacrylate-butadiene styrene, polybutadiene, or styrene acrylonitrile latex polymers, among others. In some aspects, the polymer latex additive comprises about 50% polymer. Added salts may include salts of magnesium, strontium and calcium. In particular, added salts may include: magnesium chloride MgCl2 and hydrated forms thereof, calcium chloride CaCl2), magnesium sulfate Mg2SO4 and hydrated forms thereof, strontium chloride SrCl2, and hydrated forms thereof. Other salts may also be effective, not limited to the above listed divalent cationic salts, including: barium chloride BaCl2, iron(II) chloride FeCl2, magnesium bromide MgBr2, and magnesium iodide MgI2, for example. Ionic salts may be included so as to provide a water/leather particle mixture comprising up to about 25 wt. % of one or more ionic salts. In one example, the water/leather particle mixture comprises about 2% CaCl2) and 2.5% MgCl2.6H2O (magnesium chloride hexahydrate).

Particle swelling is a result of particle collagen fibril bundles absorbing water or fluid from the particle/water mixture to form swollen fibril bundle segments 22 at step 36. The swollen fibril bundle segments are partially distressed, causing partial separation of constituent fibrils which allows improved bundle dispersion in later processing steps.

At step 38, the particle/water mixture is sheared and dispersed by a dispersion device. The dispersion device subjects particles 20 within the particle/water mixture to shear forces that separate collagen fibrils 18 from particle collagen fibril bundles 16. The dispersion process shreds particles 20 and further distresses particle collagen fibril bundles to separate collagen fibrils 18 from particle collagen fibril bundles 12.

Potential dispersion devices may be refiners such as a double disk refiner or conical refiner, as are known in paper manufacturing processes. Other potential dispersion devices may be beaters as conventionally known in paper processing machinery, such as Hollander-type beaters.

The step 38 dispersion of the particle/water mixture is conducted for a period of time required to obtain desired fibril dispersion. A desired fibril dispersion may refer to non-agglomerated pieces or leather particles throughout the dispersion. To an observer, the fibril dispersion may appear substantially uniform. With too much mixing, individual leather fibers may begin to agglomerate. The desired fibril dispersion may have no or substantially no agglomerates of leather fiber, that is, there may be a generally even dispersion or distribution of leather fibrils. Substantially no agglomerates may refer to a few visible agglomerates.

In embodiments, at step 38 the dispersed particle/water mixture may be further diluted by water to a consistency of about 1% to 3% of leather particles 18 by-weight.

At step 40, water is removed from the particle/water mixture to form a substrate wet lap. Water is removed from the particle/water mixture so that the mixture can be formed or extracted into a substrate wet lap sheet or like structure that can be physically manipulated, and de-watered so that the wet lap sheet or structure is sufficiently strong for manipulation.

The formation of a substrate wet lap may be accomplished by transferring the water/leather particle mixture to forming equipment. Appropriate forming equipment could be commercial forming equipment, such as a Fourdrinier or cylinder-type machines typically used in specialty paper manufacturing.

In embodiments, the wet lap slurry may be transferred to a wire mesh section on the forming equipment. The water drains away from the wet lap slurry through the wire mesh by gravity to form the substrate wet lap.

Before draining, wet lap slurry leather content is typically in the range of about 0.5% to 3%. Wet lap slurry water content is typically about 97% to about 99.5%.

To form a wet lap, water is removed from the wet lap slurry. Wet lap water content is reduced to a range of about 40% to 90% by-weight. Wet lap leather content is thus increased to a range of about 10% to 60% by-weight.

Water is further removed from the substrate wet lap to form a leather substrate by steps known in conventional paper manufacturing using machinery to convert wet paper pulp to a dried paper product. For instance, draining of the particle/water mixture to form a substrate wet lap may be effected through use of a Fourdrinier-type machine having various pressing and drying operations, as explained in greater detail below.

At step 42, water is removed from the substrate wet lap to form a leather substrate containing primarily by-weight of solids and a remainder by-weight of water. Step 42 may include subjecting the wet lap sheet to a wet pressing process, as generally known in paper manufacturing processes. Following wet pressing, the sheet may be further dried by conventional methods, such as heat drying, air drying and vacuum drying, to obtain an end leather substrate having a moisture content of about 2% to 8%.

As water is removed from the substrate wet lap, separated collagen fibrils 18 within the particle/water mixture physically interact with each other. As adjacent fibrils become physically engaged with each other, leather substrate collagen fibril matrix 24 is formed at step 44. Step 42 water removal may be effected through use of a Fourdrinier-type machine as explained in greater detail below.

FIG. 8 illustrates an apparatus 100 for producing a leather substrate in accordance with the steps shown in the FIG. 7 flowchart. Apparatus 100 may include elements commonly found in Fourdrinier-type paper processing machines.

In apparatus 100, waste leather 102 is selected and physically processed by shredding or grinding in shredder or grinder 104. Waste leather 102 is selected as described in step 30 of the FIG. 7 flowchart.

Initially collected waste leather 102 may come in the form of scraps from other leather tanning and treatment processes. Shredder or grinder 104 initially de-agglomerates shavings that may have become clumped due to water content or are compacted during bailing or other packaging methods. Shredder or grinder 104 also grinds larger particles to a desired size.

Physical processing by shredding or grinding forms initially shredded leather particles 106. Initially shredded leather particles 106 are screened through screening machine 108 to select leather particles 20 of a desired size and to screen out unwanted waste that may have passed through shredder 104, as described in step 32 above. Alternatively, a grinder may be used having an integrated screen to select processed leather particles having desired size criteria.

Leather particles 20 are next mixed with water 23 in a mixing chest or mixing tank 110 to form a water/leather particle mixture 112 containing a percentage of leather particles by-weight as described in step 34 above.

Leather particle collagen fibril bundles absorb water 23 from the particle/water mixture to form swollen fibril bundles 22 at step 38. Water/leather particle mixture 112 is delivered to a dispersion tank 116. Dispersion tank 116 includes a dispersion refiner 118, such as a double disk refiner, a conical refiner or Hollander-type beater, as is known in the paper manufacturing art.

Dispersion refiner 118 subjects leather particles 20 within mixture 112 to shear dispersion forces, as described in step 40 above.

Alternatively, water/leather particle mixture 112 may be separately delivered to a dispersion device and returned to mixing tank 110 for processing before drying steps are undertaken.

Water is separated from mixture 112 to form a wet lap slurry 122. Wet lap slurry 122 is transferred from dispersion tank 116 to processing machine 124 for de-watering, as described in step 40 above. Processing machine 124 may be a Fourdrinier-type machine typically used to make paper and paper products. Machine 124 has a head box 125 and a transfer assembly 126 including wire mesh section 128, one or more wet presses 130, dryer cans 132 and calendaring rollers 134.

Initially, wet lap slurry 122 is transferred to proceeding machine head box 125 and to wire mesh section 128 and wire mesh endless belt 136. Wire mesh endless belt 136 is made up of a wire meshing to allow initial draining of wet lap slurry 122 and is driven by rollers 138. Vacuums 140 may be used to assist in de-watering wet lap slurry 122.

De-watering by wire mesh section 128 sufficiently de-waters wet lap slurry 122 to form wet lap 142. Wet lap 142 is transferred further along transfer assembly 126 from wire mesh section 128 to one or more wet presses 130 for additional mechanical de-watering by presses 144.

Wet lap 142 is further transferred along assembly 126 from wet presses 130 to drier section 132 for final de-watering by drying. Drier section 132 may include a heated felt dryer, as known in the paper making art.

At this point in the process, wet lap 142 has been sufficiently de-watered to form a leather substrate 148 having desired moisture content and containing a collagen fibril matrix 24, as described in steps 42 and 44 above.

In disclosed process steps, the particle/water mixture may be treated with various materials as described in the above-referenced priority applications. In particular, specific de-wetting/dispersion aids may be added at different steps of the disclosed process.

In embodiments, the de-wetting/dispersion aids may be added to dry leather particles at an initial agitation step the process. In alternative embodiments, de-wetting/dispersion aids may be added to the particle/water mixture at a mixing step of the process. In other embodiments, the de-wetting aids may be added at multiple steps of the process, for instance at both the initial agitation step and at a later particle/water mixing step.

The de-wetting/dispersion aids may be selected types of oils.

De-wetting/dispersion aids having low water solubility and high collagen fiber affinity are effective in achieving desired de-wetting/dispersion results.

In embodiments, selected oils are organic chemicals with more than 5 carbon atoms. Oils may have from 8 to 15 carbons and are liquids at room temperature. Oils may be a wide range of types containing other atomic components, such as oxygen and others, and may come from the groups including, but not limited to alcohols, aldehydes, ethers, esters, and the like. In particular, terpenes are effective oils for this purpose. Typically, these oils have molecular weights in the range of 72 grams/mole to 400 grams/mole. In addition, materials which have a higher molecular weight or materials within this molecular weight range, which are solids at room temperature, can also be effective if they are combined with materials above, which are liquids at room temperature. For example, (2R,3S,4S,5R,6R)-2-(hydroxymethyl)-6-[(E)-3-phenylprop-2-enoxy]oxane-3,4,5-triol (gum rosin) and hexadecanol, which are both solids at room temperatures, have been found to be effective.

Potential de-wetting/dispersion aids may include:

-   Limonene -   Pinene -   Menthol -   Myrcene -   Citral -   Linalool -   Farnecene -   Caryophyllene -   Phytol -   Squalene -   Nonanol -   Deanol -   Octanol -   Benzyl alcohol -   Oleyl alcohol -   2-octyl-1-dodecanol -   Decanal -   Nonanal -   Octanal -   Hexadecanol -   Tetradecanol -   Octadecanol -   Undecanol -   Dodecanol -   Colophony (gum rosin)

The above list identifies potential de-wetting/dispersion aids and is not intended to be limiting in nature.

De-wetting/dispersion aids may be added to the leather waste before later processing steps. Referring to the flowchart of FIG. 7, in embodiments the de-wetting/dispersion aids may be added to collected leather waste at process step 30.

After collection step 30, leather waste is physically processed by cutting, shredding or grinding to create de-agglomerated leather particles 18. These particles are screened, as generally described in step 32.

De-wetting/dispersion aids may also be added as leather particles 18 are formed in the shredding or grinding steps. In embodiments, the de-wetting/dispersion aids are added to the leather waste within grinder or shredder 104 at process step 32.

The de-wetting/dispersion aids may be added in proportion to the leather waste at various ratios at steps 30 or 32. In embodiments, the by-weight ratio of leather waste to a selected wetting/dispersion may be 30-to-1. In embodiments, the by-weight ratio of leather waste to a selected wetting/dispersion may be 1-to-1. In other embodiments, by-weight ratio of leather waste to a selected wetting/dispersion may vary between 30-to-1 and 1-to-1.

In another embodiment of the disclosed method, de-wetting/dispersion aids are added to the particle/water mixture at disclosed step 34. The de-wetting/dispersion aids added at step 34 may be certain classes of selected oils and may be identical to the de-wetting/dispersion aids described above.

In the particle/water mixture, the by-weight ratio of leather particles to a selected de-wetting/dispersion aid should be a minimum of 1 part of the leather particles to 0.016 of the aid. In embodiments, the by-weight ratio of leather particles to a selected aid can be 1 part of the leather particles to 0.03 of the aid. In preferred embodiments, the by-weight ratio of leather particles to a selected aid can be 1 to X, where X is greater than 0.03.

A specific advantage of the disclosed process is the rate and amount of water which can be removed over initial formation of the wet lap at step 40 as well as later wet pressing steps at step 42 while maintaining good formation of a wet lap from wet lap slurry. This allows formation of wet lap having uniform and well-distributed leather fiber orientation.

For example, in method steps including the use of paper processing machinery (specifically a Fourdrinier-type paper machine), wet lap slurry may be transferred to a wire mesh endless belt or like apparatus to form a wet lap sheet, as described above.

The wet lap sheet retains an amount of water as it traverses along the wire mesh endless belt. This quantity of water allows leather solids within the sheet to move relative to one another to some degree, which can harm the formation of stable fiber-to-fiber and fibril-to-fibril interactions needed to create a strong leather substrate.

Through draining, the wet lap sheet loses water until a visible wet line/dry line on the wet lap sheet is formed. Once this water is removed from the wet lap sheet, the stability of the leather solids and formed fiber-to-fiber and fibril-to-fibril interactions is greatly increased.

The improved moisture drainage rate achieved through the use of de-wetting/dispersion aids allows for water to drain more quickly from the wet lap sheet. This improved draining causes the wet line/dry line on the wet lap sheet to manifest closer to point of initial wet lap slurry placement, conventionally the paper machine head box. The improved draining reduces the amount of time that wet lap slurry traverses along the wire in an undesirably wet, unstable state, thus allowing formation of a stronger leather substrate.

Prior art methods for forming substrates having poorer drainage rates results in longer wet lap slurry traversal times and therefore more opportunity for leather solids within the sheet to move relative to one another that can disrupt the formation of collagen fiber-to-fiber interactions needed to form a stronger leather substrate.

The disclosed process decreases the amount of time to drain wet lap slurry water/moisture content through process steps. Water drainage rate is improved by about two-thirds over prior art methods.

For example, within a laboratory setting, in forming a substrate wet lap sheet for formation of a finished leather substrate having a thickness of 1.5 mm, the time for water to drain from the sheet through use of prior art methods is typically 30 seconds or more. Using the disclosed process, the drainage time is less than 30 seconds and may be less than 10 seconds.

The improved drainage rate allows formation of thicker wet lap sheets over prior art processes and thus, thicker end products with improved durability and workability.

The disclosed process also allows formation of a wet lap having improved leather fiber-to-leather fiber interaction to provide improved physical properties over wet lap formed by prior art methods. The improved physical properties include improved tear resistance and tensile strength over prior art methods.

Following the forming process, the wet lap sheet may be subjected to a wet pressing process at above described step 42.

In prior art methods, the amount of pressure that can be used through the wet pressing process is limited to avoid adverse disruption of the fiber orientation and interaction between leather particles. Through the use of the disclosed process, higher pressures can be used without such adverse disruption or crushing of collagen fibril matrices within the substrate.

A cross-sectional representational view of disclosed composite leather substrate 200 is shown in FIG. 9.

Composite leather substrate 200 is formed from two leather substrates 202 and 204.

Leather substrate 202 may be a leather substrate 148, as described above, formed from process 28 utilizing waste leather 102 having the residue of protective coatings, processing agents or other substances that interfere with the steps of properly processing leather particles through the process, resulting in creation of an imperfect leather substrate having lumps or other undesirable features.

Leather substrate 204 may be a leather substrate 148, as described above, formed from process 28 utilizing waste leather 102 that is free from substances that interfere with the steps of properly executing the formation process, resulting in creation of leather substrate having a smooth, lump-free presentation surface 206.

Leather substrates 204 and 206 may be produced in parallel operating apparatuses 100, each apparatus being fed with a different waste leather 102.

In operation, each apparatus 100 would generate an interim wet lap sheet 124. The sheets from each apparatus are combined together to form a composite leather substrate 206 having an outwardly facing presentation surface 206.

The combination of the sheets may be completed prior to wet pressing at method step 42.

A cross-sectional representational view of an alternate embodiment composite leather substrate 300 is shown in FIG. 10.

Composite leather substrate 300 is formed from leather substrates 302, 304 and 306.

Leather substrate 304 may be a leather substrate 148, as described above, formed from process 28 utilizing waste leather 102 having the residue of protective coatings, processing agents or other substances that interfere with the steps of properly processing leather particles through the process, resulting in creation of an imperfect leather substrate having lumps or other undesirable features.

Leather substrate 304 is sandwiched between leather substrates 302 and 306 having outwardly facing presentation surfaces 308.

Leather substrates 302 and 306 may be leather substrates 148, as described above, formed from process 28 utilizing waste leather 102 that is free from substances that interfere with the steps of properly executing the formation process, resulting in creation of a leather substrate having a smooth, lump-free presentation surface 308.

In further alternate embodiments, a composite leather substrate may be formed from more than three leather substrates.

While this disclosure includes one or more illustrative embodiments described in detail, it is understood that each of the one or more embodiments is capable of modification and that the scope of this disclosure is not limited to the precise details set forth herein but include such modifications that would be obvious to a person of ordinary skill in the relevant art, as well as such changes and alterations that fall within the purview of the following claims. 

What is claimed is:
 1. A method of forming a leather substrate material comprising the steps of: (a) collecting leather material; (b) shredding and screening the leather waste material to provide leather material particles comprising collagen fiber bundles; (c) combining the leather material particles with a portion of a fluid or water to provide a water/leather material particle solution or a fluid/leather material particle solution; (d) allowing collagen fiber bundles of the leather material particles to absorb at least a portion of the fluid or water; (e) shearing the leather material particles; (f) dispersing the leather material particles; (g) forming a wet lap or pulp comprising the leather material particles; and, (h) removing at least a portion of the fluid or water from the fluid/leather material particle solution or from the water/leather material particle solution.
 2. The method of claim 1 wherein step (a) comprises adding a de-wetting/dispersion aid to the leather waste material.
 3. The method of claim 2 wherein the de-wetting/dispersion aid comprises an oil.
 4. The method of claim 3 wherein the oil has a molecular weight in the range of 72 grams/mole to 400 grams/mole.
 5. The method of claim 1 wherein step (b) comprises adding a de-wetting/dispersion aid to the leather waste material.
 6. The method of claim 5 wherein the de-wetting/dispersion aid comprises an oil.
 7. The method of claim 6 wherein the oil has a molecular weight in the range of 72 grams/mole to 400 grams/mole.
 8. The method of claim 1 wherein step (c) comprises adding a de-wetting/dispersion aid to the water/leather material particle solution or the fluid/leather material particle solution.
 9. The method of claim 8 wherein the de-wetting/dispersion aid comprises an oil.
 10. The method of claim 9 wherein the oil has a molecular weight in the range of 72 grams/mole to 400 grams/mole.
 11. The method of claim 1 wherein step (b) comprises screening the leather waste material through apertures varying in diameter form 0.625 inches to 0.75 inches.
 12. A method of forming a leather substrate material comprising the steps of: (a) providing leather particles from a first leather source, said leather particles comprising collagen fiber bundles; (b) combining the leather material particles with a fluid to form a first leather material solution; (c) agitating the first leather material solution; (d) removing at least a portion of the fluid from the first leather material solution; and, (e) forming a first leather substrate.
 13. The method of claim 12 wherein step (a) or step (b) comprises adding a de-wetting/dispersion aid.
 14. The method of claim 13 wherein the de-wetting/dispersion aid comprises an oil.
 15. The method of claim 14 wherein the oil has a molecular weight in the range of 72 grams/mole to 400 grams/mole.
 16. The method of claim 12 wherein step (a) comprises screening the leather particles through apertures varying in diameter form 0.625 inches to 0.75 inches.
 17. The method of claim 12 comprising the steps of: (f) providing leather particles from a second leather source, said leather particles comprising collagen fiber bundles; (g) combining the leather material particles with a fluid to form a second leather material solution; (h) agitating the second leather material solution; (i) removing at least a portion of the fluid from the second leather material solution; (j) forming a second leather substrate; and, (k) combining the first leather substrate with the second leather substrate to form a composite leather substrate.
 18. A leather substrate material formed by a process comprising: (a) providing leather particles from a leather source, said leather particles comprising collagen fiber bundles; (b) combining the leather material particles with a fluid to form a leather material solution; (c) removing at least a portion of the fluid from the leather material solution; and (d) adding a de-wetting/dispersion aid comprising an oil at either of step (a) and/or step (b).
 19. The leather substrate material of claim 18 wherein the oil has a molecular weight in the range of 72 grams/mole to 400 grams/mole.
 20. A composite leather substrate material formed by a process comprising: (a) providing leather particles from a first leather source, said leather particles comprising collagen fiber bundles; (b) combining the leather material particles with a fluid to form a first leather material solution; (c) removing at least a portion of the fluid from the first leather material solution to form a first leather substrate; (d) providing leather particles from a second leather source, said leather particles comprising collagen fiber bundles; (e) combining the leather material particles with a fluid to form a second leather material solution; (f) removing at least a portion of the fluid from the second leather material solution to form a second leather substrate; and, (g) combining the first leather substrate with the second leather substrate to form a composite leather substrate.
 21. The composite leather substrate material of claim 20 wherein step (a) and/or step (b) and/or step (d) and/or step (e) comprises adding a de-wetting/dispersion aid.
 22. The composite leather substrate material of claim 21 wherein the de-wetting/dispersion aid comprises an oil.
 23. The composite leather substrate material of claim 22 wherein the oil has a molecular weight in the range of 72 grams/mole to 400 grams/mole. 